Window Rebate Insulation Block With Modular Air-Duct Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of insulating blocks for window rebates is complex and costly due to the need for custom-made molds for each window size, especially for foamed plastic insulation, which limits versatility and efficiency.
Innovation Solution
The insulating block is composed of two standardized parts with recesses that can be combined to form a continuous length, allowing for the creation of air ducts and undercuts without complex manufacturing, using standardized endless profiles that can be cut to size, simplifying production and enabling versatile use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-made molds are used for each window size, then the insulating block can be precisely tailored to specific window dimensions, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The insulating block is divided into multiple standardized segments that can be assembled together. Each segment has a standard cross-sectional shape that can be produced with simple molds, while the required length is achieved by combining multiple segments. This segmentation allows precise adaptation to different window lengths without requiring custom molds for each size.
2Manufacturing precision
If custom-made molds are used for each window size, then the insulating block matches specific window dimensions, but the production cost increases
Solution Approach 1:
A small number of universal mold types are designed that can produce standardized insulating block segments suitable for multiple window sizes. By combining these universal segments in different quantities and configurations, insulating blocks for various window dimensions can be produced using the same basic molds, significantly reducing tooling costs while maintaining fit precision.
3Ease of manufacture
If standardized parts are used, then manufacturing becomes simpler and more versatile, but creating complex shapes like undercuts and angled air ducts becomes difficult
Solution Approach 1:
Complex features such as air ducts and undercuts are created by nesting or combining multiple standardized segments with complementary geometries. The segments are designed with mating features that allow them to be assembled into complex three-dimensional shapes, including angled configurations and integrated ventilation channels, while each individual segment remains simple to manufacture.
4Device complexity
If a one-piece insulating block is used, then the structure is simple, but manufacturing complex shapes requires very complex molds with slides
Solution Approach 1:
The insulating block is divided into multiple simple standardized segments that can be assembled together to form complex shapes. Each segment has a simple geometry that can be produced with basic molds, eliminating the need for complex one-piece molds with slides and ejector mechanisms. The segmentation allows complex final shapes to be achieved through assembly rather than single-step molding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for easy and cost-effective production of insulating blocks that provide thermal insulation and ventilation functions, expanding their application and simplifying manufacturing by using standard parts that can be assembled into various configurations, including angled air ducts, without the need for custom molds.
Implementation Method 1
They consist of an insulating material, in particular in order to achieve thermal insulation and / or sound insulation
Implementation Method 2
They consist of an insulating material, in particular in order to achieve thermal insulation and / or sound insulation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to an insulating block (14) for insulating arrangement in a rebate area (13) between a frame (2) and a casement (3) of a window, door or the like, in particular a roof window (1). The insulating block (14) is composed of at least two insulating block parts (21, 22) running along its length and at least one, each with at least one recess (41, 42, 43, 44, 45, 46) in air duct path (47,48,49) formed in each of the insulating block parts (21,22).